Collator with moveable stitcher over saddle conveyor system

Abstract

A signature collator and stitcher is disclosed which provides high output, multiple path operation, automatic repair, and multispeed operation. The collator provides a saddle conveyor which moves the saddles perpendicular to the direction of the saddles so that the signature assemblies are carried in a direction perpendicular to the fold for better control. The saddles are positioned close to each other so that a high density system results in which high production rates can be obtained with relatively low conveyor speeds. The signature feed delivers the signatures to the saddles along an inclined path to provide a component of movement in the direction of conveyor movement for high speed operation. The stitcher operates on the fly for high speed operation and utilizes a simple linkage to produce linear stitcher head movement. The discharge mechanism includes eccentrically mounted nip rolls so that the throat of the nip rolls moves in the direction of conveyor movement when the signatures are raised into the nip rolls by a tucker blade.

What is claimed is: 
     
       1. A collator comprising a closed loop endless conveyor including a plurality of signature supporting means extending perpendicular to the conveying direction, a plurality of signature feed means adjacent said conveyor operable to progressively locate folded signatures in position supported by said signature supporting means to produce assemblies of signatures in which the folds thereof extend perpendicular to the conveying direction, stitching means adjacent to said conveyor operable to stitch together assembled signatures delivered thereto by said signature supporting means, and delivery means operable to remove stitched assemblies from said conveyor, said signature feed means including a sensor operable to detect when a misfeed occurs resulting in an incomplete assembly, said sensor operating to disable downstream signature feed means as well as stitching means and delivery means as said incomplete assembly passes thereby, said conveyor operating to return said incomplete assembly to a feed means feeding the missing signature for subsequent completion, stitching, and removal from said conveyor. 
     
     
       2. A collator as set forth in claim 1 wherein said signature feed means operates to feed a folded signature folded edge trailing along a path inclined at an acute angle in the direction of movement of said signature supporting means, said feed means including opening means operable to open the leading edge of said signature as it reaches the associated supporting means. 
     
     
       3. A collator as set forth in claim 2, wherein said feed means maintains full control of said signatures until after the leading edges thereof are substantially past the associated supporting means. 
     
     
       4. A collator comprising a closed loop conveyor providing saddles at intervals along the length thereof extending perpendicular to conveyor travel, a plurality of feeders operable to progressively position folded signatures on said saddles with the signature folds supported on the saddles, stitcher means operable on the fly to stitch assembled signatures, and discharge means providing nip rolls providing a throat reciprocable along a path substantially parallel to the direction of conveyor movement, said discharge means comprising a tucker blade operable to move assembled signatures from a supporting saddle into said throat. 
     
     
       5. A collator as set forth in claim 4, wherein said nip rolls are journaled on eccentric axes to cause said throat to move with reciprocating movement generally in the direction of conveyor movement. 
     
     
       6. A collator comprising a closed loop conveyor providing saddles at intervals along the length thereof extending perpendicular to conveyor travel, a first group of feeders, a second group of feeders, a separate stitcher positioned along said conveyor downstream from each of said groups of feeders, a separate delivery mechanism positioned adjacent to said conveyor downstream from each stitcher, said collator being operable for dual path operation in which each group of feeders cooperates with the adjacent downstream stitcher and delivery mechanism to complete assembled signatures, said collator being operable with single path operation by disabling one of said stitchers and its associated discharge mechanism whereby signatures assembled by all of said feeders are stapled by the other stitcher and discharged by the other discharge mechanism. 
     
     
       7. A collator as set forth in claim 6 including a drive operable to drive said conveyor, feeders, stitchers, and discharge mechanisms at at least two different operating speeds. 
     
     
       8. A collator for folded signatures measured perpendicular to the fold, said collator comprising a closed loop conveyor havng a plurality of saddles at uniform intervals theralong, said saddles extending perpendicular to the direction of conveyor movement and being operable to support said signatures along their folds, said saddles being spaced from each other by a distance less than the size of a signature measured in the direction perpendicular to the fold, a plurality of signature feeders positioned adjacent said conveyor operable to progressively position signatures on said saddles as said saddles progress past said feeders to produce signature asemblies, and stitcher means operable to stitch said signature assemblies as they are carried past said stitcher means by said saddles, said stitcher moving with said saddles as said signatures are stitched, said stitcher including stitcher heads mounted on a support driven for reciprocation in timed relation to the movement of said saddles, said support being guided for straight-line reciprocating movement in a direction parallel to saddle movement by pairs of similar linkages. 
     
     
       9. A collator as set forth in claim 8, wherein discharge means is provided which include nip rolls providing a throat that moves in the direction of saddle movement, and tucker means operable to move the assembled signatures from an associated saddle into said throat as said throat moves with said saddle. 
     
     
       10. A collator for folded signatures measured perpendicular to the fold, said collator comprising a closed loop conveyor having a plurality of saddles at uniform intervals therealong, said saddles extending perpendicular to the direction of conveyor movement and being operable to support said signatures along their folds, said saddles being spaced from each other by a distance less than the size of the signatures meaured in the direction perpendicular to the fold, a plurality of signature feeders positioned adjacent said conveyor operable to progressively position signatures on said saddles as said saddles progress past said feeders to produce signature assemblies, stitcher means operable to stitch said signature assemblies as they are carried past said stitcher means by said saddles, discharge means which include nip rolls providing a throat that moves in the direction of saddle movement, and tucker means operable to move the asembled signatures from an associated saddle into said thorat as said throat moves with said saddle. 
     
     
       11. A collator as set forth in claim 10, wherein said nip rolls are journaled on eccentric axes to cause said throat to reciprocate generally in the direction of saddle movement. 
     
     
       12. A collator comprising a closed loop endless conveyor including a plurality of signature supporting means extending perpendicular to the conveying direction, a plurality of signature feed means adjacent said conveyor operable to progressively locate folded signatures in position supported by said signature supporting means to produce assembies of signatures in which the folds thereof extend perpendicular to the conveying direction, stitching means adjacent to said conveyor operable to stitch together assembled signatures delivered thereto by said signature supporting means, and delivery means operable to remove stitched assemblies from said conveyor, said conveyor including upper and lower reaches joined by curved end portions, and guide means for controlling signature movement along at least one of said curved end portions. 
     
     
       13. A collator as set forth in claim 12, wherein said guide means are located at the descending curved end portion along which said signature supporting means move from said upper reach to said lower reach, said guide means extending along the path of said conveyor and operating to cause the open edge of said signatures to trail as the signature supporting means associated therewith move down along said descending curved end. 
     
     
       14. A collator for folded signatures measured perpendicular to the fold, said collator comprising a closed loop conveyor having a plurality of saddles at uniform intervals therealong, said saddles extending perpendicular to the direction of conveyor movement and being operable to support said signatures along their folds, said saddles being spaced from each other by a distance less than the size of a signature measured perpendicular to the fold, a plurality of signature feeders positioned adjacent said conveyor operable to progessively position signatures on said saddles as said saddles progress past said feeders to produce signature assemblies, and stitcher means operable to stitch said signature assembies as they are carried past said stitcher means by said saddles, said collator further comprising anvil means carried by an endless conveyor mounted below said closed loop conveyor, said anvil means comprising a plurality of anvils corresponding to said plurality of saddles. 
     
     
       15. A collator as set forth in claim 14, wherein said feeders operate to feed signatures toward said saddles folded edge trailing and operate to open said signatures as they reach said saddles. 
     
     
       16. A collator as set forth in claim 15, wherein said feeders maintain control of said signatures until after the open edge thereof is past said saddles. 
     
     
       17. A collator as set forth in claim 16, wherein said feeders feed signatures along a path inclined in the direction of conveyor movement to facilitate movement of said signatures onto said saddles. 
     
     
       18. A collator as set forth in claim 17, wherein said stitcher means moves with said saddles as said signatures are stitched. 
     
     
       19. A collator for folded signatures measured perpendicular to the fold, said collator comprising a closed loop conveyor having a plurality of saddles at uniform intervals therealong, said saddles extending perpendicular to the direction of conveyor movement and being operable to support said signatures along their folds, said saddles being spaced from each other by a distance less than said dimension, a plurality of signature feeders positioned adjacent said conveyor operable to progressively position signatues on said saddles as said saddles progress past said feeders to produce signature assemblies, and stitcher means operable to stitch said signature assemblies as they are carried past said stitcher means by said saddles, said stitcher means being movable with said saddles as said signatures are stitched. 
     
     
       20. A collator as set forth in claim 19, wherein said stitcher means includes stitcher heads mounted on a support driven for reciprocation in timed relationship to the movement of said saddles.